Method of forming a heater core connector

ABSTRACT

A small bend radius connector for a heater core is shown, wherein a first end of the connector has a rectangular cross section, a second end of the connector has a circular cross section, and wherein a size, a weight, and a cost of production of the connector are minimized.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of U.S. patent applicationSer. No. 11/521,878 HEATER CORE CONNECTOR filed on Sep. 15, 2006, herebyincorporated herein by reference in its entirety.

FIELD OF THE INVENTION

The present invention relates to a connector and more particularly to aconnector having a minimized bend radius for use with a heater core in avehicle.

BACKGROUND OF THE INVENTION

Heater core connectors are typically used to connect heat exchangertanks to other components in a vehicle. Ideally, the connectors have lowprofiles to comply with packaging requirements and facilitate a fluidtight seal between the heat exchanger tank and the other components.

Prior art connectors are typically comprised of single or multiplestamped pieces that are brazed together with the heat exchanger to forma fluid-tight connection therebetween. However, the brazing employed onmultiple-piece connectors often leaves the connection prone to leakingas well as limiting the available options for connection to extensiontubes. Typical stamped single-piece connectors only allow for circularinlet or outlet configurations and thereby limit the fluid circuit andsubsequently the efficiency of the heat exchanger device.

To overcome this problem, heater core connectors have been formed from asingle piece of material that is bent to form a desired angle, whereinthe brazing step is eliminated. Typical design guides recommend that aminimum bend radius of a tube section is two and one half times adiameter of the section. Such a bend radius yields connectors havinglengths that are two to three times the diameter of the connector. Suchlengths are undesirable due to packaging limitations that require theconnector to have smaller profiles.

It would be desirable to produce a connector having a small bend radiusfor a heater core of a vehicle, wherein a size, a weight, and a cost ofproduction thereof are minimized and wherein the connector militatesagainst leakage.

SUMMARY OF THE INVENTION

Harmonious with the present invention, a connector having a small bendradius for a heater core of a vehicle, wherein a size, a weight, and acost of production thereof are minimized and wherein the connectormilitates against leakage, has surprisingly been discovered.

In one embodiment, a tube comprises: a hollow conduit having a firstend, a spaced apart second end, and an intermediate portion, theintermediate portion having a bend formed therein, wherein a radius ofthe bend is less than a diameter of the conduit.

In another embodiment, a tube comprises: a hollow conduit having a firstend, a spaced apart second end, and an intermediate portion, wherein thefirst end is adapted to be connected to a heat exchanger tank, thesecond end is adapted to be connected to a connector tube, and theintermediate portion includes a bend formed therein, wherein the bendhas a radius that is less than a diameter of the hollow conduit and theconduit has a length that is less than three times the diameter thereof.

A method of forming a tube for a heat exchanger is disclosed, the methodcomprising the steps of: providing a hollow conduit; cutting the conduitto a desired length; and forming a bend in the conduit, wherein the bendis approximately ninety degrees and has a bend radius that is less thanthe diameter of the tube.

BRIEF DESCRIPTION OF THE DRAWINGS

The above, as well as other objects and advantages of the invention,will become readily apparent to those skilled in the art from readingthe following detailed description of a preferred embodiment of theinvention when considered in the light of the accompanying drawings inwhich:

FIG. 1 is a cross-sectional side view of a tube in accordance with anembodiment of the invention; and

FIG. 2 is a perspective view of the conduit illustrated in FIG. 1, afterthe conduit has been cut to a desired length;

FIG. 3 is a perspective view of the conduit illustrated in FIG. 1, afterthe conduit has been formed into a substantially Z-shape shape;

FIG. 4 is a perspective view of the conduit illustrated in FIG. 1, aftera bend of the conduit has been formed into a desired shape;

FIG. 5 is a perspective view of the conduit illustrated in FIG. 1, aftera flange has been formed on a first end of the conduit and a desireddiameter of a second end of the conduit has been formed; and

FIG. 6 is a perspective view of the conduit illustrated in FIG. 1, aftera punch has been used to expand the second end of the conduit to adesired shape.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The following detailed description and appended drawings describe andillustrate various exemplary embodiments of the invention. Thedescription and drawings serve to enable one skilled in the art to makeand use the invention, and are not intended to limit the scope of theinvention in any manner. In respect of the methods disclosed andillustrated, the steps presented are exemplary in nature, and thus, theorder of the steps is not necessary or critical.

FIG. 1 shows a conduit 10 in accordance with an embodiment of theinvention. In the embodiment shown, the conduit 10 is formed fromaluminum. However, other materials can be used to form the conduit 10 asdesired. The conduit 10 includes a diameter d, a length L, a first end12, a spaced apart second end 14, and an intermediate portion 16. Theintermediate portion 16 is disposed between the first end 12 and thesecond end 14. In the illustrated embodiment, the length L of theconduit 10 is less than three times (3×) the diameter d thereof.However, other configurations can be used as desired.

The first end 12 is substantially rectangular in cross section and isadapted to be connected to an inlet or outlet of a heat exchanger tank(not shown). It is understood that the first end 12 may have other crosssectional shapes and can be connected to other components as desiredwithout departing from the scope and spirit of the invention. A flange18 is formed on the conduit 10 adjacent the first end 12. The flange 18is adapted to facilitate connection with the inlet or outlet of the heatexchanger tank.

The second end 14 is substantially circular in cross section and isadapted to be connected to an extension tube (not shown). It isunderstood that the second end 14 may have other cross sectional shapesand can be connected to other components as desired without departingfrom the scope and spirit of the invention. The second end 14 of theconduit 10 includes a flange 22 extending radially outwardly from theconduit 10 at an angle. An inner wall 20 of the conduit 10 adjacent tothe second end 14 includes a sloped ridge 24. The sloped second ridge 24is adapted to abut a distal end of the connector tube. Optionally, anO-ring (not shown) can be disposed between an outer wall of theextension tube and the inner wall 20 of the conduit 10 adjacent theflange 22.

The intermediate portion 16 includes a bend 26 formed therein. The bend26 is approximately ninety degrees and includes a bend radius r. In theembodiment shown, the bend radius r is less than the diameter d of theconduit 10. A length L2 of a first leg of the conduit 10 adjacent thefirst end 12 thereof is also less than the diameter d of the conduit 10.

In use, the first end 12 of the conduit 10 is received by the inlet oroutlet of the heat exchanger tank, so the inlet or outlet abuts theflange 18. The second end 14 of the conduit 10 receives the connectortube. When assembled, the sloped second ridge 24 of the conduit 10 abutsa distal end of the connector tube. The O-ring disposed between theouter wall of the connector tube and the inner wall 20 of the conduit 10adjacent the flange 22 forms a substantially fluid tight sealtherebetween. A fluid (not shown) is caused to flow through theconnector tube into the conduit 10 and into the inlet of the heatexchanger tank. It is understood that the flow pattern is reversed ifthe conduit 10 is connected to an outlet of a heat exchanger tank.

Since the bend radius r of the conduit 10 is smaller than the diameter dof the conduit, the size of the package required to house the conduit 10and the costs associated with the shipment thereof are minimized.Further, since the first end 12 of the conduit 10 has a rectangularcross section, the conduit 10 can be connected directly to the inlet oroutlet of the heat exchanger tank, which are typically rectangular incross section, without the use of additional tubes or conduits.Additionally, since the second end 14 of the conduit 10 has a circularcross section, the conduit 10 can be connected directly to the connectortube, which is typically circular in cross section, without the use ofadditional tubes or conduits. Accordingly, the cost required forproducing the heater core and the time and effort required for theassembly thereof are minimized.

A method of forming the conduit 10 illustrated in FIG. 1 will now bedescribed. A hollow conduit 110 is provided, as shown in FIG. 2.Preferably, the hollow conduit 110 is formed from aluminum or analuminum alloy. However, other materials may be used to form the conduit110 as desired. The conduit 110 is cut to produce a desired length L.The conduit 110 includes a first end 112, a spaced apart second end 114,and an intermediate portion 116 disposed between the first end 112 andthe second end 114.

The conduit 110 is then placed in a die (not shown) and formed into asubstantially Z-shape by crushing the conduit 110 where a bend 126 is tobe formed, as shown in FIG. 3. The die is also used to form the firstend 112 of the hollow conduit 110 into a substantially rectangularshape.

Thereafter, the conduit 110 is placed in a second die (not shown). Thesecond die is used to complete the bend 126 in the conduit 110 and toshape the second end 114 of the conduit 110 in a process similar tohydroforming. The first end 112 of the conduit 110 is plugged to form asubstantially fluid tight seal. A fluid (not shown) capable oftransmitting hydraulic force, such as water, for example, is disposed inthe conduit 110. A ram is introduced into the second end 114 of theconduit 110 to hydraulically expand the conduit 110 and form the bend126 into the desired shape, as shown in FIG. 4. Thereafter, the seconddie is used to form a second ridge 124 on the conduit 110 and to form adesired diameter d of the conduit 110. A flange 118 is formed on theconduit 110 in the second die, as shown in FIG. 5.

Finally, a punch (not shown) is introduced into the second end 114 ofthe conduit 110. The punch is used to expand the conduit 110 at thesecond end 114 to form the flange 122 as shown in FIG. 6.

From the foregoing description, one ordinarily skilled in the art caneasily ascertain the essential characteristics of this invention and,without departing from the spirit and scope thereof, can make variouschanges and modifications to the invention to adapt it to various usagesand conditions.

1. A method of forming a tube for a heat exchanger comprising the stepsof: providing a hollow conduit; cutting the conduit to a desired length;and forming a bend in the conduit, wherein the bend has a bend radiusthat is less than the diameter of the tube.
 2. The method according toclaim 1, further comprising the step of forming a first end of theconduit into one of a substantially rectangular cross section, asubstantially oval cross section, and a substantially circular crosssection.
 3. The method according to claim 2, further comprising the stepof forming a second end of the conduit into one of a substantiallyrectangular cross section, a substantially oval cross section, and asubstantially circular cross section.
 4. The method according to claim3, further comprising the step of expanding the first end of the conduitto form a flange thereon.
 5. The method according to claim 1, furthercomprising the steps of disposing the conduit into a first die andcrushing the conduit into a substantially Z-shape.
 6. The methodaccording to claim 5, further comprising the steps of disposing theconduit into a second die, causing a fluid to be contained in theconduit, and compressing the fluid to cause the conduit to be expandedto a desired shape.
 7. The method according to claim 1, wherein theconduit is formed from a metal.
 8. The method according to claim 1,wherein the conduit is formed from one of aluminum and an aluminumalloy.
 9. A method of forming a tube for a heat exchanger comprising thesteps of: providing a hollow conduit; cutting the conduit to a desiredlength to form a first end and a second end on the conduit; pressurizingan interior of the conduit; and forming a bend in the conduit during apressurization thereof, wherein the bend has a bend radius that is lessthan the diameter of the tube.
 10. The method according to claim 9,further comprising the step of forming the first end of the conduit intoone of a substantially rectangular cross section, a substantially ovalcross section, and a substantially circular cross section.
 11. Themethod according to claim 10, further comprising the step of forming thesecond end of the conduit into one of a substantially rectangular crosssection, a substantially oval cross section, and a substantiallycircular cross section.
 12. The method according to claim 11, furthercomprising the step of expanding the first end of the conduit to form aflange thereon.
 13. The method according to claim 9, further comprisingthe steps of placing the conduit into a first die and crushing theconduit into a substantially Z-shape.
 14. The method according to claim13, further comprising the steps of placing the conduit into a seconddie, causing a fluid to be contained in the conduit, and compressing thefluid to cause the conduit to be expanded to a desired shape.
 15. Themethod according to claim 9, wherein the conduit is formed from a metal.16. The method according to claim 9, wherein the conduit is formed fromone of aluminum and an aluminum alloy.
 17. A method of forming a tubefor a heat exchanger comprising the steps of: providing a hollowconduit; cutting the conduit to a desired length to form a first end anda second end on the conduit; pressurizing an interior of the conduit;crushing at least a portion of the conduit; plugging the first end ofthe first conduit; forming a bend in the conduit, wherein the bend has abend radius that is less than the diameter of the tube.
 18. The methodaccording to claim 17, further comprising the steps of forming each ofthe first end of the conduit and the second end of the conduit into oneof a substantially rectangular cross section, a substantially oval crosssection, and a substantially circular cross section.
 19. The methodaccording to claim 17, further comprising the step of expanding thefirst end of the conduit to form a flange thereon.
 20. The methodaccording to claim 17, wherein the conduit is formed from a metal.